Air cushion inflation machine

ABSTRACT

A machine converts a web of preformed pouches, which are defined by transverse seals extending from a remote edge, into inflated dunnage units. A sealing arrangement is positioned to provide a longitudinal seal intersecting the transverse seals to close the preformed pouches and form a dunnage unit. The sealing arrangement has at least two sealing belts. Each belt is positioned so that respective first sides engage a surface of the web and pull the web through sealing elements positioned on either side of the web. A heating element is on a second side of the first belt not engaging the web. A compliant material is on a second side of the second belt not engaging the web. As the web passes between the heating element and compliant material, imperfections in the web are smoothed by the compliant material and the layers of the web are sealed by the heating element.

RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No.61/907,347, filed Nov. 21, 2013, the entire disclosure of which ishereby incorporated by reference.

INCORPORATION BY REFERENCE

This application incorporates by reference the entire disclosures of, tothe extent they are not conflicting with the present application, U.S.patent application Ser. No. 13/543,082 entitled AIR CUSHION INFLATIONMACHINE, filed Jul. 6, 2012, and U.S. Provisional Patent Application No.61/505,261 entitled AIR CUSHION INFLATION MACHINE, filed Jul. 7, 2011.

BACKGROUND

The present invention relates to fluid filled units and moreparticularly to a novel and improved machine for converting a web ofpreformed pouches to dunnage units and will be described with particularreference thereto. It will be appreciated, however, that the inventionis also amenable to other applications.

Machines for forming and filling dunnage units from sheets of plasticare known. Machines which produce dunnage units by inflating preformedpouches in a preformed web are also known. For many applications,machines which utilize preformed webs are used.

The present invention provides a new and improved apparatus and methodwhich addresses the above-referenced problems.

SUMMARY

In one aspect of the present invention, it is contemplated that amachine converts a web of preformed pouches, which are defined bytransverse seals extending from a remote edge, into inflated dunnageunits. A sealing arrangement is positioned to provide a longitudinalseal intersecting the transverse seals to close the preformed pouchesand form dunnage units. The sealing arrangement has at least two sealingbelts. Each belt is positioned so that respective first sides of thebelts engage a surface of the web and pull the web past at least onesealing element. In one exemplary embodiment, a heating element is on asecond side of the first belt not engaging the web and a compliantmaterial is on a second side of the second belt not engaging the web. Asthe web passes between the heating element and compliant material,imperfections in the web are smoothed by the compliant material and thelayers of the web are sealed by the heating element. The presentapplication also discloses that compliant or softer material or acompliant or softer belt spreads the pressure applied to the sealed areamore evenly, which results in a more uniform seal.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings which are incorporated in and constitute apart of the specification, embodiments of the invention are illustrated,which, together with a general description of the invention given above,and the detailed description given below, serve to exemplify theembodiments of this invention.

FIG. 1 is a plan view of an exemplary embodiment of air cushionmaterial;

FIG. 1A is a top plan view of an exemplary embodiment of an air cushioninflation machine;

FIG. 1B is a view taken along lines 1B-1B in FIG. 1A;

FIG. 2 is a view similar to FIG. 1A with a web of air cushion materialinstalled in the air cushion inflation machine;

FIG. 2A is a plan view of inflated and sealed air cushions;

FIG. 3 is a side view of an element made of compliant material;

FIG. 3A is an end view of an element made of compliant material;

FIG. 4 is an illustration of a heating element having a higherresistance portion and a lower resistance portion;

FIG. 5 is a plot of DC heating element voltage switched between maximumand minimum voltages according to a duty cycle;

FIG. 5A is a plot of an analog DC heating element voltage that isadjustable between maximum and minimum voltages;

FIG. 6 is a flow chart illustrating an exemplary embodiment of a controlalgorithm for an air cushion inflation machine;

FIG. 7A is a flow chart illustrating an exemplary embodiment of an idlesequence of a control algorithm for an air cushion inflation machine;

FIGS. 7B-7C illustrate an example of states of components of an aircushion inflation machine when the air cushion inflation machine is inan idle condition;

FIG. 8A is a flow chart illustrating an exemplary embodiment of a startsequence of a control algorithm for an air cushion inflation machine;

FIGS. 8B-8E illustrate an example of states of components of an aircushion inflation machine when the air cushion inflation machine is in astart condition;

FIG. 9 is a flow chart illustrating an exemplary embodiment of a runsequence of a control algorithm for an air cushion inflation machine;

FIG. 10A is a flow chart illustrating an exemplary embodiment of a stopsequence of a control algorithm for an air cushion inflation machine;

FIGS. 10B-10C illustrate an example of states of components of an aircushion inflation machine when the air cushion inflation machine is in astop condition;

FIG. 11 illustrates one embodiment of alternating current (AC) to directcurrent (DC) converter (AC/DC converter) providing DC power to a system;

FIG. 12 a second embodiment of the alternating current (AC) to directcurrent (DC) converter (AC/DC converter) providing DC power to thesystem;

FIGS. 13 and 13A are perspective views of an exemplary embodiment of anair cushion inflation machine;

FIG. 14 is a perspective view of a dual belt air cushion inflationmachine, such as the air cushion inflation machine illustrated by FIGS.7B and 7C;

FIG. 14A is a side view of the air cushion inflation machine illustratedby FIG. 14;

FIG. 15A is a front view of sealing components of the air cushioninflation machine illustrated by FIGS. 13 and 13A;

FIG. 16 is a perspective view of the sealing and clamp assemblies of theair cushion inflation machine shown in FIG. 14;

FIG. 17 is a view taken as indicated by lines 12-12 in FIG. 16;

FIG. 17A is an enlarged portion of FIG. 17;

FIG. 17B is a view similar to FIG. 17A illustrating routing of inflationcushion material into the machine;

FIG. 18 is a rear perspective view of a sealing assembly of the aircushion inflation machine illustrated by FIG. 13A;

FIG. 19 is a rear view of a sealing assembly of the air cushioninflation machine illustrated by FIG. 13A;

FIG. 20 is a perspective view of a sealing assembly of the air cushioninflation machine shown in FIG. 14;

FIG. 21 is a view taken as indicated by lines 16-16 in FIG. 20;

FIG. 22 is a view taken as indicated by lines 17-17 in FIG. 20;

FIG. 23 is a perspective view of a clamping assembly of the air cushioninflation machine shown in FIG. 14;

FIG. 24 is a view taken as indicated by lines 19-19 in FIG. 23;

FIG. 25 is a partial rear view of the sealing and clamping assembliesshown in FIG. 16;

FIG. 26 is a sectioned perspective view with the section being taken asindicated by lines 21-21 in FIG. 25;

FIG. 27 is a sectional view taken along the plane indicated by lines21-21 in FIG. 25;

FIG. 28 is a partial rear view of the sealing and clamping assembliesshown in FIG. 16;

FIG. 29 is a sectioned perspective view with the section being taken asindicated by lines 24-24 in FIG. 28;

FIG. 30 is a sectional view taken along the plane indicated by lines24-24 in FIG. 28;

FIG. 31 is a perspective view of a part of an air cushion inflationmachine illustrated by FIG. 13A;

FIG. 32 is a view taken as indicated by lines B-B in FIG. 31;

FIG. 33 is a component diagram of an air cushion inflation machine;

FIG. 34 is a sectional view of the heated sealing element and thecompliant material;

FIG. 35 is a perspective view showing an inside of the air cushioninflation machine;

FIG. 36 is a perspective view of another exemplary embodiment of an aircushion inflation system showing a curved belt surface;

FIG. 37 is a perspective view of a part of an air cushion inflationsystem showing a curved belt surface;

FIG. 38 is a perspective view of a part of an air cushion inflationsystem showing a curved belt surface;

FIG. 39 is a perspective view of a part of an air cushion inflationsystem showing a curved belt surface and the blower assembly;

FIG. 40 is a perspective view of a part of an air cushion inflationsystem showing a curved belt surface;

FIG. 41 is a view of a part of an air cushion inflation system showing acurved belt surface;

FIG. 42 is a perspective view of a part of an air cushion inflationsystem showing a curved belt surface;

FIG. 43 is a perspective view of a part of an air cushion inflationsystem showing a curved belt surface;

FIG. 44 is a perspective view of a part of an air cushion inflationsystem showing a curved belt surface;

FIG. 45 is a perspective view of a part of an air cushion inflationsystem showing a curved belt surface;

FIG. 46 is a perspective view of a belt assembly including a curved beltsurface;

FIG. 47 is a perspective view of a belt assembly including a curved beltsurface;

FIG. 48 is a perspective view of a part of an air cushion inflationsystem showing a blower system;

FIG. 49 is a perspective view of a belt assembly including a curved beltsurface;

FIG. 50 is a perspective view of a belt assembly including a curved beltsurface;

FIG. 51 is a perspective view of a spindle for an air cushion inflationsystem;

FIG. 52 is a side view of a spindle for an air cushion inflation system;and

FIGS. 53 and 54 are perspective views of a spool for an air cushioninflation system.

DETAILED DESCRIPTION OF ILLUSTRATED EMBODIMENT

As described herein, when one or more components are described as beingconnected, joined, affixed, coupled, attached, or otherwiseinterconnected, such interconnection may be direct as between thecomponents or may be indirect such as through the use of one or moreintermediary components. Also as described herein, reference to a“member,” “component,” or “portion” shall not be limited to a singlestructural member, component, or element but can include an assembly ofcomponents, members or elements.

FIG. 1 illustrates an example of a preformed web 10 that can beprocessed by a new machine 50 (See machine examples of FIGS. 1A, 7C, 13,and 14) to produce inflated air cushions 12 (See FIG. 2A). The preformedweb can take a wide variety of different forms. Any preformed web thatcan be inflated, sealed and then separated from the machine 50 can beused. Examples of acceptable webs 10 include, but are not limited to,any of the webs shown and/or described by U.S. Pat. Nos. D633792;7897220; 7897219; D630945; 7,767,288; 7,757,459; 7,718,028; 7,694,495;D603705; 7,571,584; D596031; 7,550,191; 7,125,463; 7,125,463; 6,889,739;or 7,975,457; or United States Patent Application Publn. Nos.20100281828A1; 20100221466A1; 20090293427A1; and 20090110864A1, whichare all incorporated herein by reference in their entirety. It should bereadily apparent that other preformed webs could be used in the machine50 to produce dunnage units.

The illustrated web 10 is formed of a heat sealable plastic film, suchas polyethylene. However, any heat sealable material can be used. Theweb 10 includes superposed top and bottom, elongate layers 14, 16connected together along spaced seal and inflation side edges 18, 20.Each of the edges may be either a fold or a seal. The superposed layers14, 16 are hermetically connected along the seal side edge 18. In theillustrated embodiment, the inflation side edge 20 is perforated. Inanother embodiment, the inflation side edge 20 is not perforated and aline of perforations is included in one of the layers 14, 16, with theline of perforations being spaced apart from and running parallel to theinflation side edge 20. In another embodiment, the inflation side edge20 is not perforated and a line of perforations is included in each ofthe layers 14, 16, with the lines of perforations being spaced apartfrom and running parallel to the inflation side edge 20. In yet anotherembodiment, the layers 14, 16 are not connected together at theinflation side edge.

A plurality of longitudinally spaced, transverse seals 22 join the topand bottom layers 14, 16. Referring to FIGS. 1 and 2, the transverseseals 22 extend from the seal edge 18 to within a short distance of theinflation edge 20 to form pouches 26. An optional pocket 23 is formedbetween the transverse seals 22 and the inflation edge 20. A pocket isnot formed if the inflation edges of the layers 14, 16 are notconnected. A line of perforations 24 extends through the top and bottomlayers. FIG. 2A illustrates a length of the web 10 after it has beeninflated and sealed to form inflated cushions 12. An inflation seal 42,closes the pouches 26 defined by the transverse seals 22 and the sealside edge 18 to form the inflated cushions. The illustrated inflatedcushions 12 include gaps G (see FIG. 2A) between each pair of adjacentcushions. A web 10 that is specially constructed to form the gaps G wasused in the illustrated embodiment. In other embodiments, a web 10 maybe used that does not form the illustrated gaps G (see FIG. 2A).

FIGS. 1A-1B and 2 schematically illustrate an exemplary embodiment of amachine 50 for converting a preformed web 10 (see FIG. 1) to inflatedcushions 12 (see FIG. 2A). The machine 50 may take a wide variety ofdifferent forms and the inflation, sealing and separation arrangementsdescribed below may be in the order/positions described or in any otherorder/position that facilitates inflation of the web 10, sealing of theweb, and separation of the web from the machine 50. In the exampleillustrated by FIGS. 1A-1B and 2, the machine 50 includes an inflationarrangement 160, a sealing arrangement 162, a clamping arrangement 110including a compliant material 112, and a web separation device 158. Inone embodiment, the compliant material 112 is a silicone foam rubber,closed cell material having less than a Shore A hardness. The compliantmaterial 112 may be coated with acrylic adhesive on both sides. In oneembodiment, the compliant material 112 is usable up to about 390° F. Asillustrated in FIG. 3, in one embodiment, it is contemplated that thecompliant material 112 has a length 2000 of about 4.38″, a height 2002of about ¼″, and a thickness 2004 of about 1/16″.

The inflation arrangement 160 can take a wide variety of differentforms. Any arrangement capable of providing air under increased pressure(above atmosphere) to the pouches 26 can be used. In the illustratedembodiment, the inflation arrangement 160 includes a hollow,longitudinally extending guide pin 56 and a blower 60. Referring to FIG.2, a web 10 is routed from a supply and the pocket 23 is placed aroundthe guide pin 56, such that the guide pin 56 is between the inflationside edge 20 and the transverse seals 22. The guide pin 56 aligns theweb as it is pulled through the machine 50. The guide pin 56 includes aninflation opening 102 that is fluidly connected to the blower 60 by aconduit 104. The blower 60 inflates the web pouches 26 as the web movespast the inflation opening 102.

In an exemplary embodiment, the inflation arrangement 160 also includesa blower control 106. The blower control 106 can take a wide variety ofdifferent focus. For example, the blower control 106 can be anyarrangement that is operable to control the flow rate and/or pressure ofair provided by the inflation arrangement 160 to the pouches 26. In oneembodiment, the blower control 106 is a speed controller that controlsthe operation speed of the blower 60. Such a speed controller speeds theblower up to provide air at higher pressures and/or flow rates andreduces the blower speed to reduce the pressure and/or flow rate. Inanother embodiment, the blower control 106 comprises a flow controlvalve in the conduit 104 between the blower 60 and the inflation opening102. The conduit 104 may be short as illustrated by FIG. 1B or long asillustrated by FIG. 1A. The conduit may perform or be adapted to performthe function of the web separation device 158.

The sealing arrangement 162 forms the seal 42 (FIG. 2) to create sealedinflated cushions 12. The sealing arrangement 162 can take a widevariety of different forms. For example, the sealing arrangement 162 canbe any arrangement capable of forming a hermetic seal between the layers14, 16. Referring to FIG. 1B, the sealing arrangement 162 includes aheated sealing element 64, a temperature control arrangement 165, anassembly positioning device 66, the compliant material 112, a pair ofdrive rollers 68, a belt speed control 67, and a pair of drive belts 70.The belt speed control 67 electronically communicates with an encoder 80to control the speed of the belts 68. For example, based on a feedbackloop, the encoder determines the relative speeds of the belts 68. If therelative speeds of the belts 68 are not within a predeterminedtolerance, the encoder 80 determines an error has occurred. In oneembodiment, if the encoder 80 determines an error occurs, the encoder 80causes the motors to stop the belts 68. Although the encoder 80 isillustrated as part of the belt speed control 67, it is to be understoodthat other embodiments in which the encoder 80 is separate from the beltspeed control 67 are also contemplated.

In an alternate embodiment, a pair of cooling elements are provideddownstream of the heated sealing element 64. Each belt 70 is providedaround its respective drive roller 68. Each belt 70 is driven by itsrespective drive roller 68. The speed of the drive rollers 68 and belts70 are controlled by the belt speed control 67. The belts 70 are inclose proximity or engage one another, such that the belts 70 pull theweb 10 proximate to the heat sealing element 64. The seal 42 (see FIG.2) is formed as the web 10 passes through first the heated sealingelements 64.

The heating element 64 can take a wide variety of different forms. Anyarrangement capable of raising the temperature of the layers 14 and/or16 to a point where the layers will hermetically bond together can beused. For example, the heating element 64 may be a heating wire, ceramicelement or other member that provides heat upon the application ofpower. For example, resistance of the heating element 64 causes theheating element 64 to heat up when voltage is applied across the heatingelement. In the illustrated embodiment, the heating element 64 is aheating wire having a length between about 1″ to about 12″. It is alsocontemplated that the heating element 64 is a substantially flat wirehaving a thickness of about 0.011″.

The heating element 64 (wire) also includes at least one low resistanceportion 82 and at least one high resistance portion 84. As illustratedin FIG. 1B, the heating element 64 (wire) includes two relatively lowerresistance portions 82 and one relatively higher resistance portion 84.In one embodiment, the lower resistance portions 82 are copper or are atleast include a copper coating or other low resistance coating toprovide for relatively high electrical conductivity and relatively lowelectrical resistance. The lower resistance portions 82 havesubstantially no electrical resistance, which results in substantiallyno heat or heat dissipation along those lower resistance portions 82.The higher resistance portion 84 includes a material that producesrelatively low electrical conductivity and relatively high electricalresistance. Consequently, substantially all of the heat is dissipatedalong the relatively higher resistance portion 84 of the heating element64.

In one embodiment, the higher resistance portion 84 is between about 1″long and about 9″ long. In another embodiment, the higher resistanceportion 84 is between about 2″ long and about 8″ long. In anotherembodiment, the higher resistance portion 84 is between about 3″ longand about 7″ long. In another embodiment, the higher resistance portion84 is between about 4″ long and about 6″ long. In another embodiment,the higher resistance portion 84 is about 4.5″ long. In the embodimentillustrated in FIG. 4, the lower resistance portion 82, which includes acopper coating, has a width 2010 of about 0.118″ (3.0 mm), a length 2012of about 7.165″ (182 mm), and a thickness of about 0.006″ (0.15 mm). Thehigher resistance portion 84, which does not include a copper coating,has a width 2014 of about 0.110″ (2.8 mm) at a point “A”, a length 2016of about 4.84″ (123 mm), and a thickness of about 0.006″ (0.15 mm).

With reference again to FIG. 1B, the relatively shorter length of thehigher resistance portion 82 provides for greater control of theelectrical resistance and temperature (e.g., ±1 degree, 2, 5 or 10degrees,). For example, in one exemplary embodiment the higherresistance portion is only provided in an area where the seal is beingformed. This shorter, higher resistance, portion in only the area wherethe seal is being formed results in more consistent electricalresistance and temperature control than results over a longer highelectrically resistive material that has portions outside the area wherethe seal is being formed. In addition, the relatively shorter length andmore consistent electrical resistance of the higher resistance portion84 results in faster temperature changes when electrical current isapplied and removed from the heating element 64. The faster temperaturechanges along the heating element 64 are discussed in more detail below.

The assembly positioning device 66 is capable of moving the belt 70associated with the compliant material 112 away from the belt 70associated with the heating element 64. For example, the assemblypositioning device 66 may cause the belt 70 associated with thecompliant material 112 to move upward and away from the belt 70associated with the heating element 64. At times, it is desirable tomove the belt 70 associated with the compliant material 112 away fromthe belt 70 associated with the heating element 64 to position the webbetween the belts 70.

With further reference to FIG. 1B, in the illustrated embodiment thetemperature control arrangement 165 is coupled to the heating element 64to control the temperature of the heating element 64. In thisembodiment, the temperature control arrangement 165 is coupled to thelow resistance portion 82 of the heating element 64. However, otherembodiments in which the temperature control arrangement 165 is coupledto the high resistance portion 84 of the heating element 64 are alsocontemplated.

The temperature control arrangement 165 may take a wide variety ofdifferent forms. Any arrangement capable of controlling the heatingelement 64 can be used. In one exemplary embodiment, the temperaturecontrol arrangement 165 includes a thermocouple. The thermocouple may becoupled to the heating element 64 in a variety of different ways. In oneexemplary embodiment, the heating element 64 includes a ceramic memberthat is encapsulated with the thermocouple. The encapsulation of theceramic member with the thermocouple provides for very accuratemeasurement of the temperature of the heating element 64. Thetemperature measured by the thermocouple is used to adjust the power(e.g., current, voltage, and/or duty cycle) applied to the heatingelement 64 and thereby control the temperature of the heating element64.

In one exemplary embodiment, the current passing through the heatingelement 64 is used to determine the resistance of the heating element.The resistance of the heating element 64 is, in turn, used to determinethe temperature of the heating element 64. For example, the resistanceof the heating element 64 can be calculated based on the current passingthrough the heating element 64 and the voltage across the heatingelement. The voltage used in the calculation may be acquired in a widevariety of different ways. For example, the voltage used in thecalculation may be the voltage applied by the power supply or thevoltage may be directly measured by optional bypass leads 84 a, 84 b asillustrated by FIG. 1B. The current used in the calculation may beacquired in a wide variety of different ways. For example, the currentused in the calculation may be measured using a Hall Effect sensor or alow resistance, high precision feedback resistor. In one embodiment,where the current is measured with a Hall Effect Sensor, the temperaturecontrol arrangement 165 is a solid state device including a Hall Effectsensor for measuring resistance on the heating element 64. In anotherembodiment the current is measured with a low resistance, high precisionfeedback resistor that is in series with the heating element. Forexample, the low resistance, high precision feedback resistor may be a20mΩ resistor.

In another exemplary embodiment, the current applied to the heatingelement is controlled or held constant and the voltage drop across theheating element 64 is used to determine the resistance of the heatingelement. The resistance of the heating element 64 is, in turn, used todetermine the temperature of the heating element 64. For example, theresistance of the heating element 64 can be calculated based on thecurrent passing through the heating element 64 and the voltage acrossthe heating element. The voltage used in the calculation may be acquiredin a wide variety of different ways. For example, the voltage used inthe calculation may be the voltage applied by the power supply or thevoltage may be directly measured by optional bypass leads 84 a, 84 b asillustrated by FIG. 1B. The current used in the calculation may beacquired in a wide variety of different ways. For example, the currentused in the calculation may be a fixed current applied by the powersupply. In this embodiment, the duty cycle of the current can beincreased to increase the temperature of the heating element and theduty cycle of the current can be decreased to decrease the temperatureof the heating element.

In one embodiment, it is contemplated that direct current (DC) is usedto power the heating element 64. Powering the heating element 64 withdirect current (DC), as opposed to alternating current (AC), permits thetemperature control arrangement 165 to calculate resistance (i.e. as afunction of current and voltage) in the heating element 64 (e.g., thehigh resistance portion 84 of the heating element 64). The temperatureof the heating element 64 (e.g., high resistance portion 84 of theheating element 64) is determined (e.g., calculated or correlated) basedon the calculated resistance. Determining the temperature of the heatingelement 64 based on the calculated resistance provides a relativelyfaster temperature response than if alternating current (AC) is used topower the heating element 64. In one embodiment, the DC power is cycledon and off according to a duty cycle to achieve a desired set pointtemperature of the high resistance portion 84 of the heating element 64.For example, with respect to FIG. 5, a voltage of the DC power isswitched between zero (0) volts and 5.5 volts according to a duty cycleto achieve a desired temperature of the heating element 64. For example,the duty cycle is increased (i.e. more on time) to increase thetemperature and the duty cycle is decreased (i.e. more off time) todecrease the temperature.

Referring to FIG. 5A, in another embodiment, which is discussed in moredetail below, a voltage of the DC power is controlled to a continuous(e.g., constant) voltage output between, for example, zero (0) volts and5.5 volts to achieve the desired temperature of the heating element 64.For example, the DC voltage is increased to increase the temperature andthe DC voltage is decreased to decrease the temperature.

Once the temperature control arrangement 165 determines the temperatureof the heating element 64 (e.g., high resistance portion 84 of theheating element 64), the heating element 64 is capable of controllingthe power supplied to the heating element 64 for achieving ormaintaining a temperature of the high resistance portion 84 of theheating element 64 within a predetermined temperature range. Forexample, if the temperature of the high resistance portion 84 of theheating element 64 is above the predetermined temperature range, thetemperature control arrangement 165 may cause the amount of directcurrent (DC) supplied to the heating element 64 to be reduced.Conversely, if the temperature of the high resistance portion 84 of theheating element 64 is below the predetermined temperature range, thetemperature control arrangement 165 may cause the amount of directcurrent (DC) supplied to the heating element 64 to be increased.

FIG. 1B illustrates an exemplary embodiment of a clamping arrangement110 including the compliant material 112. The clamping arrangement 110is positioned to pinch the top and bottom layers 14, 16 of the preformedweb 10 together. The clamping arrangement 110 inhibits air underpressure P (FIG. 2) in the inflated webs from applying force to themolten longitudinal seal 42. This prevents the air under pressure P fromblowing the molten longitudinal seal 42 open and/or creating undesirablestresses that weaken the longitudinal seal.

The clamping arrangement 110 can take a wide variety of different forms.For example, the clamping arrangement 110 can be any arrangement capableof squeezing the layers 14, 16 in an area where the material of thelayers is molten, soft or not yet completely solidified and cool. In theillustrated embodiment of FIG. 1B, the clamping arrangement 110 includesa pair of drive rollers 68, a pair of drive belts 70, the compliantmaterial 112, and an optional assembly positioning device 66. Each belt70 is disposed around its respective drive roller 68. Each belt 70 isdriven by its respective drive roller 68. The drive rollers 68 may becoupled to the drive rollers 68 (see FIG. 1B) of the heat sealing belts70 (see FIG. 1B) or the drive rollers 68 may be driven independently ofthe drive rollers 68 (see FIG. 1B). The belts 70 engage one another,such that the belts 70 pull the web 10 and pinch the web as the webpasses by the heat sealing element 64 and the compliant material 112.Another exemplary clamping arrangement is disclosed by U.S. Pat. No.7,571,584, which is incorporated herein by reference in its entirety.

In the illustrated embodiment, the compliant material 112 is on anopposite side of the belt 70 than the web 10. As the web passes by theheat sealing element 64 and the compliant material 112, the compliantmaterial acts to keep substantially constant pressure on the web whilethe web passes by the heat sealing element 64. For example, thecompliant material 112 is a material having a spongy and/or rubberycharacteristic. Therefore, as the web passes by the compliant material112, imperfections in the web (e.g., wrinkles) are reduced since thespongy and/or rubbery compliant material 112 can slightly deform as theimperfections pass by the compliant material 112. In other words, the“forgiving” nature of the compliant material 112 results in thesubstantially constant pressure on the web as the web passes by the heatsealing element 64. The substantially constant pressure on the webresults in a better seal.

It is contemplated that the compliant material 112 is at least as longas the high resistance portion 84 of the heat sealing element 64.However, the compliant material 112 may be longer as illustrated, forexample, at least twice or even three times, or more as long, asillustrated by FIG. 18.

Referring to FIG. 2, the web separation device 158 can take a widevariety of different forms. For example, when the web 10 includes a lineof perforations at or along the seal side edge 18, the web separationdevice 158 may be a blunt surface, when the inflation edge 20 is notperforated the separation device 158 may be a sharp knife edge, and whenthe layers 14, 16 are not connected together at the seal side edge theweb separation device may be omitted. In the illustrated embodiment, theweb separation device 158 is positioned along the path of travel of theweb prior to the heat sealing element 64. The web separation device 158is positioned prior to the heat sealing element 64 so that the webseparation device opens the pocket 23 of the web at the same time thepouches 26 are being sealed. However, the web separation device 158 canbe positioned anywhere along the path of travel of the web. For example,the web separation device 158 can be positioned before the sealingarrangement 162, after the sealing arrangement, before the inflationopening 102, or after the inflation opening 102. The illustratedseparation device 158 extends from the pin 56. However, the separationdevice 158 may be mounted to the machine 50 in any manner. Theseparation device 158 opens the web 10 at or near the inflation sideedge 20 as the web moves through the machine 50.

FIG. 6 illustrates an exemplary embodiment of a control algorithm 300for the inflation machine 50. In the illustrated embodiment, the controlalgorithm 300 includes an off state 302, an idle sequence 304, a startsequence 306, a run sequence 308, and a stop sequence 310. In the offstate, the inflation arrangement 160 and the sealing arrangement 162 areboth turned off.

FIG. 7A illustrates the idle sequence 304 and FIGS. 7B-7C illustrate thestates of the components of the machine 50 when the machine executes theidle sequence. FIGS. 7B and 7C illustrate an exemplary embodiment wherethe sealing arrangement 110 illustrated by FIGS. 1A and 1B is idle. Whenthe machine 50 is turned on 400, the machine begins the idle sequence304. In the idle sequence 304, the sealing element 64 is set 402 to anidle temperature by the temperature control arrangement 165. Theinflation arrangement 160 is set 404 to an idle output or speed by theinflation control 106. Referring to FIG. 7C, in an exemplary embodiment,the belt speed control 67 stops the belts 70, 70 and the positioningdevice 66 positions the belt 70 to either separate from or connect tothe web 10. As such, when the machine 50 executes the idle sequence 304,the inflation arrangement 160 pre-inflates the pouches 26 and theheating element 64 is pre-heated, but spaced apart from the web. Thispre-inflation and pre-heating reduces the time it takes for the machine10 to transition to production of inflated cushioning members. In oneexemplary embodiment, the web is pre-inflated, but the heating element84 is not preheated. For example, when the heating element 84 is shortand has a fast response time, the heating element heats up very quicklyand does not need to be preheated in the idle sequence of FIG. 7A.

FIG. 8A illustrates the start sequence 306 and FIGS. 8B-8E illustratethe states of the components as the machine 50 executes the startsequence. When the machine 50 is turned 420 (FIG. 7A) from the idlesequence 304 to the start sequence 306, the machine 50 optionallyidentifies 500 the type of material being inflated and sealed. Forexample, the machine may determine that that the material is a pillowtype material (see for example FIG. 1) or a wrap type material (see forexample U.S. Pat. Nos. D633792 and D630945). The machine may alsooptionally determine the size and type of material the web 10 is madefrom in this step.

In the start sequence 304, the sealing elements 64 are raised from theidle temperature to a sealing temperature (when the sealing temperatureis higher than the idle temperature or when the sealing elements are notpre-heated) by the temperature control arrangement 165 at steps 502 and504. At step 506, the inflation arrangement 160 is optionally ramped up508 from the idle output or speed to the inflation output or speed. Theramp up from the idle output or speed to the inflation output or speedmay be controlled in a variety of different ways. For example, theinflation arrangement may be ramped up until an inflation pressure setpoint in the web 10 is reached, until the inflation device reaches aspeed set point, and/or until a predetermined period of time has elapsedafter the inflation device reaches a speed set point.

In the exemplary embodiment, the machine closes (See FIG. 8E) thesealing element 64 at steps 512 and 514, when the machine is not alreadyclosed. Very little or no material is wasted upon start up of themachine. That is, the first pouches 26 that are fed into the machine 50are inflated and sealed, rather than being un-inflated orunder-inflated.

In the exemplary embodiment, the machine optionally determines 520whether the inflation arrangement 160 has already been ramped to theinflation speed or output after the sealing element has closed on theweb 10. Once the sealing element 64 is closed on the web 10, the beltspeed control 67 starts 524 the belts 70, 70 (see arrows in FIG. 8E) andthe machine begins producing sealed and inflated cushions and moves on525 to the run sequence.

In one exemplary embodiment, control of the sealing arrangement 162,inflation arrangement 160, and/or the drive rollers 68 are interrelated.For example, the sealing arrangement 162, inflation arrangement 160,and/or the drive rollers 68 are controlled based on input from one ormore of the temperature control arrangement 165, belt speed control 67and/or the blower control 106. By interrelating the sealing arrangement162, inflation arrangement 160, and/or the drive rollers 68, theair/pressure in the pouches and/or the quality of the inflation seal 41,may be precisely controlled.

In an exemplary embodiment, the belt speed may be controlled based onfeedback from the encoder 80, the blower control 106 and/or thetemperature control arrangement 165. If the temperature of the sealingelement 64 is lower than a predetermined set point, the belt speed maybe reduced to ensure that enough heat is applied to the web to form ahigh quality seal. Similarly, if the temperature of the sealing element64 is higher than a predetermined set point, the belt speed may beincreased to ensure that too much heat is not applied to the web andthereby ensure that a high quality seal is formed. If the output orspeed of the inflation arrangement 160 is lower than a predetermined setpoint, the belt speed may be reduced to ensure that the pouches 26 areoptimally filled. In an exemplary embodiment, the encoder 80, the bloweroutput or speed and/or the heating element temperature 64 arecontinuously controlled to bring the blower output or speed and theheating element temperature to predetermined set points. The speed ofthe belts may be continuously updated based on the feedback from theblower control 106 and/or the temperature control arrangement 165 tooptimize the seal quality and pouch filling, especially as the inflationarrangement and/or the sealing element are being ramped to their normaloperating conditions.

In an exemplary embodiment, the temperature of the sealing element 64may be controlled based on feedback from the encoder 80, the inflationcontrol 106 and/or the belt speed control 67. If the belt speed is lowerthan a predetermined set point, the temperature of the sealing element64 may be reduced to ensure that too much heat is not applied to the weband ensure that a high quality seal is formed. Similarly, if the beltspeed is higher than a predetermined set point, the temperature of thesealing element 64 may be increased to ensure that enough heat isapplied to the web and a high quality seal is formed. In an exemplaryembodiment, the encoder 80, the blower output or speed and/or the beltspeed control 67 are continuously controlled to bring the blower outputor speed and the belt speed to predetermined set points. The temperatureof the sealing element 64 may be continuously updated based on thefeedback from the blower control 106 and/or the belt speed to optimizethe seal quality and pouch filling, especially as the inflationarrangement and/or the belt speed are being ramped to their normaloperating conditions.

In an exemplary embodiment, the inflation arrangement 160 may becontrolled based on feedback from the encoder 80, the belt speed control67 and/or the temperature control arrangement 165. If the temperature ofthe sealing element 64 is lower than a predetermined set point, theblower output or speed may be changed to ensure proper inflation andsealing of the air filled cushions. If the belt speed is lower than apredetermined set point, the blower output or speed may be changed toensure proper inflation and sealing of the air filled cushions. In anexemplary embodiment, the belt speed and/or the heating elementtemperature are continuously controlled to bring the belt speed and/orthe heating element temperature to predetermined set points. The blowerspeed or output may be continuously updated based on the feedback fromthe encoder 80, the drive roller control 67 and/or the temperaturecontrol arrangement 165 to optimize the seal quality and pouch filling,especially as the belt speed and/or the sealing temperature are beingramped to their normal operating conditions.

In one exemplary embodiment, the temperature of the sealing arrangement162 is independent of feedback from inflation control and belt control.In this embodiment, belt speed may be controlled based solely onfeedback from the sealing arrangement 162. Similarly, in thisembodiment, the inflation arrangement 162 may be controlled based solelyon feedback from the sealing arrangement 162. In an exemplaryembodiment, the machine 50 is programmed with a control loop that bringsthe sealing arrangement 162 to a temperature set point and to hold thetemperature at the set point. During execution of this control loop, thecurrent temperature of the sealing arrangement is monitored and is usedto control the belt speed and inflation arrangement 162.

FIG. 9 illustrates an exemplary embodiment of a run sequence 308 wherecontrol of the sealing arrangement 162, inflation arrangement 160,and/or the drive rollers 68 are interrelated. It should be appreciatedthat the control of the sealing arrangement 162, inflation arrangement160, and/or the drive rollers 68 can be interrelated in a wide varietyof different ways and that FIG. 9 illustrates one of the manypossibilities. In FIG. 9, relationships of the belt speed and inflationdevice speed or output with respect to the temperature of the heatingdevice are set 600. The belt speed and inflation device speed or outputare set 602 based on the current temperature of the sealing element 64.In another embodiment, where the response time of the sealing element isfast, the temperature of the sealing element may be set based on thebelt speed and/or the inflation device speed. In the illustratedexample, the belt speed and inflation device speed or output are set 602based on the current temperature of the sealing element 64. At optionalstep 604, if the set point of the sealing element 64 and/or the setpoint of the inflation arrangement 160 have changed (for example, due touser input), the updated set points are retrieved 606 and therelationships of the belt speed and inflation device speed or outputwith respect to the temperature of the heating device are reset 600. Ifthe set point of the sealing element 64 and/or the set point of theinflation arrangement 160 have not changed, the sequence checks 608 tosee if the sealing element 64 has reached the temperature set point. Ifthe sealing element 64 has not reached the temperature set point, thebelt speed and inflation device speed or output are updated 602 based onthe current temperature of the sealing element 64. This process isrepeated until the sealing element 64 reaches the temperature set point.

Once the sealing element 64 is at the temperature setting 610 and thebelt speed and inflation device output are at the corresponding setpoints 612, the encoder 80 ensures the relationships between the beltspeed and inflation device speed are maintained. Alternatively, in otherembodiments, the relationships between the belt speed and inflationdevice speed or output with respect to the temperature of the heatingdevice may optionally be disregarded 614 until the machine is stopped orfor a predetermined period of time or until an event is detected thattriggers updating of the belt speed and/or inflation device output. Atthis point, the machine 50 is running at a full or optimal speed 615 andcontinues to do so until an inflation setting changes 616, a heatsetting changes 618, or the machine is stopped 620. When an inflationdevice setting changes, the inflation device speed or output isincreased or decreased 622 based on the new setting. When a temperaturesetting changes, the heating device temperature set point is increasedor decreased 624 based on the new setting. When the machine is stopped,the sequence proceeds 626 to the stop sequence 310.

FIG. 10A illustrates an exemplary stop sequence and FIGS. 10B-10Cillustrate examples of conditions of components of the machine 50 duringthe stop sequence. In the stop sequence 310, the belt speed control 67stops 700 the belts 70, 70 (FIG. 7C). At optional step 702, if thematerial is pillow type material, the inflation arrangement 160 isbraked 703. At step 704, the sequence optionally confirms that the belts70 have been stopped. Once the belts 70 are stopped, the machineoptionally opens 706 the sealing element 64. At optional step 708, ifthe material is wrap type material, the sequence allows 710 apredetermined period of time to elapse and then the inflationarrangement 160 is braked 712. At step 714, the sequence confirms 716that both the belts 70 and the inflation arrangement 160 are stopped andthe sequence optionally returns to the idle sequence 304 or the stopstate 302.

With reference to FIG. 11, in one embodiment, alternating current (AC)power is supplied to an alternating current to direct current (DC)converter (AC/DC converter) 3000. The AC/DC converter 3000 provides DCpower to, for example, motors 88 (see FIG. 13) that drive the belts 70(see FIG. 1B), the blower 60, and a DC/DC converter 3004. The DC powersupplied to the motors, blower, and/or the DC/DC converter can be anyappropriate DC voltage, such as 12V, 24V, or 48V. In one embodiment, theDC/DC converter 3004 receives the DC power from the AC/DC converter 3000and is programmable to provide a DC power output that is adjustablebetween zero (0) volts and an appropriate maximum DC voltage for theheating element 64, such as, for example 5.5 Volts DC. It iscontemplated that the DC power output between zero (0) volts and themaximum DC voltage is a continuous analog DC output that is quicklyadjustable to control the temperature of the heating element 64. Inanother embodiment, the DC/DC converter 3004 receives is programmable toprovide a DC power output having a current output that is adjustable tocontrol the temperature of the heating element 64.

The DC power output of the DC/DC converter 3004 may be used to controlthe heater temperature control 165 (see FIG. 1B). In one embodiment, theDC power output of the DC/DC converter 3004 is included in a controlloop with the heater temperature control 165 for controlling thetemperature of the heating element 64. In one exemplary embodiment, theoutput voltage of the DC/DC converter is increased to increase thetemperature of the heating element 64 or decreased to decrease thetemperature of the heating element 64. In another exemplary embodiment,the output current of the DC/DC converter is increased to increase thetemperature of the heating element 64 or decreased to decrease thetemperature of the heating element 64.

In one embodiment, the heater temperature control 165 (see FIG. 1B)receives a desired set point temperature from, for example, a user input3006 (see FIG. 1B) such as a knob or switch that may be included on theheater temperature control 165. Alternatively, the heater temperaturecontrol 165 receives the desired set point temperature from an externalcomputing device. The heater temperature control 165 electronicallycommunicates a signal to the DC/DC converter 3004 based on a currenttemperature of the heating element 64 (see FIG. 1B) and the set pointtemperature. In one embodiment, the current temperature of the highresistance portion 84 (see FIG. 1B) of the heating element 64 (see FIG.1B) is determined based on a calculated resistance of the highresistance portion as described above. For example, voltage measurementsmay be obtained at the ends 84 a, 84 b (see FIG. 1B) of the highresistance portion 84 (see FIG. 1B) or by using the voltage applied bythe DC/DC converter 3004. Then, the current through the high resistanceportion 84 (see FIG. 1B) is measured, for example with a Hall Effectsensor or a low resistance, high precision feedback resistor asdescribed above. The resistance is determined based on the voltage andthe current according to the equation Resistance (R)=Voltage (V)/Current(I).

If, for example, the set point temperature is 300° F. and the currenttemperature of the heating element 64 (see FIG. 1B) is determined to be280° F., the heater temperature control 165 (see FIG. 1B) electronicallycommunicates a signal to the DC/DC converter 3004 to increase the DCvoltage output of the DC/DC converter 3004 which, in turn, increases theresistance of the high resistance portion 84 (see FIG. 1B) of theheating element 64 (see FIG. 1B). Since the temperature of the highresistance portion 84 (see FIG. 1B) of the heating element 64 (see FIG.1B) is related to the resistance of the high resistance portion 84 (seeFIG. 1B), changing the resistance of the high resistance portion 84 (seeFIG. 1B) correspondingly changes the temperature of the high resistanceportion 84 (see FIG. 1B). It is contemplated that the temperature of theheating element is measured and calculated very often. In one exemplaryembodiment, the temperature of the heating element is measured andcalculated at more than 100 Hz, such as at about 281 Hz. As such, theheated sealing element 64 is monitored every 10 ms or less, 5 ms orless, 2 ms or less, or 1 ms or less, instead of about every 20 ms if thesystem uses AC power operated at 50 Hz and sampling is done on fullwaves. This allows for very precise control of the temperature of theheating element, such as between 1° F. and 5° F.

It is contemplated that the signal communicated to the DC/DC converter3004 is based on the level of temperature changed (e.g., resistancechange) desired to achieve the set point temperature of the heatingelement 64 (see FIG. 1B). For example, if it is desired to raise thetemperature of the heating element 64 to achieve the set pointtemperature by only 10° F., the signal communicated to the DC/DCconverter 3004 will cause the DC/DC converter 3004 to change the DCvoltage output a relatively smaller amount than if it is desired toraise the temperature of the heating element 64 (see FIG. 1B) by 50° F.In other words, the signal communicated to the DC/DC converter 3004 willcause the DC/DC converter 3004 to change the DC voltage outputproportionally according to the level of resistance change (e.g.,temperature change) needed to bring the temperature of the heatingelement 64 (see FIG. 1B) to the set point temperature. In that regard,if it is desired to raise the temperature of the heating element 64 (seeFIG. 1B) to achieve the set point temperature, the signal communicatedto the DC/DC converter 3004 will cause the DC/DC converter 3004 toincrease the DC voltage output, while if it is desired to lower thetemperature of the heating element 64 (see FIG. 1B) to achieve the setpoint temperature, the signal communicated to the DC/DC converter 3004will cause the DC/DC converter 3004 to lower the DC voltage output.

In the embodiment discussed above, the resistance is changed to achievea desired temperature change of the high resistance portion 84 (see FIG.1B) of the heating element 64 (see FIG. 1B). Alternatively, athermocouple is provided to directly measure the temperature of the highresistance portion 84 (see FIG. 1B) of the heating element 64 (see FIG.1B).

With reference to FIG. 12, in another embodiment, alternating current(AC) power is supplied to two alternating current to direct current (DC)converters (AC/DC converters) 3010, 3012. The first of the AC/DCconverters 3010 provides DC power (e.g., a fixed DC voltage) to, forexample, motors 88 (see FIG. 13) that drive the belts 70 (see FIG. 1B),and the blower 60. Any appropriate DC voltage for the motors 88 andblower 60 may be selected. For example, this DC voltage may be 12V, 24V,or 48V. The second of the AC/DC converters 3012 is programmable toprovide an adjustable DC power output between zero (0) volts and anappropriate maximum DC voltage for the heating element 64, such as 5.5Volts DC. However, any maximum DC voltage may be selected (as long as itis high enough to achieve the maximum temperature of the heatingelement), since the output is adjustable. It is contemplated that the DCpower output between zero (0) volts and the maximum DC voltage is acontinuous analog DC output and is quickly adjustable to control thetemperature of the heating element. The output DC voltage of the AC/DCconverter is increased to increase the temperature of the heatingelement 64 or decreased to decrease the temperature of the heatingelement 64.

The machine 50 may take a wide variety of different forms. FIGS. 13,13A, 15A, 18, 19, 31, and 32 and FIGS. 14, 14A, 16, 17, 20, and 21illustrate two non-limiting, exemplary embodiments of the machine 50 indetail. In the example illustrated by FIGS. 13, 13A, 15A, 18, 19, 31,and 32, the machine 50 includes an inflation arrangement 102, and asealing arrangement 110. FIG. 13 illustrates the machine 50 with a cover802 disposed over the sealing arrangement 110. FIG. 13A illustrate themachine 50 with the cover removed.

Referring to FIGS. 13, 13A, 15A, 18, 19, 31, and 32, the web 10 isrouted from a supply to and around a pair of elongated, transverselyextending guide rolls 854. The web 10 is then routed to a longitudinallyextending guide pin 856. The guide pin 856 is disposed between theinflation edge 20 and the transverse seals 22 of the web 10. The guidepin 856 aligns the web as it is pulled through the machine.

The inflation arrangement 110 can take a wide variety of differentforms. Referring to FIG. 18, in the illustrated embodiment, theinflation arrangement 110 includes the hollow, longitudinally extendingguide pin 856. The blower and blower control are disposed in a housing1204 (FIG. 13) of the machine 50.

With reference to FIG. 13A, the web 10 passes from the guide rolls 854to the pin 856 and the separation device 158 before passing into thesealing and clamping arrangement 110. With reference to FIG. 14A, themachine 50 includes the encoder 80 to measure the web 10 travel andencoders 81 to measure the operating speeds the motors. With referenceto FIG. 15A, the encoder 80 is illustrated before the separation device158 and the sealing and clamping arrangement 110. With reference toFIGS. 18 and 19, the encoders 81 are illustrated as separate from themotors 88, but may be part of the motor assemblies.

With reference to FIG. 31, the machine 50 is illustrated showing theguide pin 56, the separation device 158, and the sealing and clampingarrangement 110. FIG. 32 illustrates a cross-sectional view of themachine 50 along the B-B in FIG. 31. With reference to FIG. 32, theheated sealing element 64 and compliant material 112 are illustrated inthe sealing and clamping arrangement of the machine 50.

FIGS. 14, 14A, 16, 17, 17A, 17B, and 20-30 illustrate a secondnon-limiting, exemplary embodiment of an inflation machine 50 in detail.In the example illustrated by FIGS. 14, 15, 16, 17, 17A, 17B, and 20-30,the machine 50 includes an inflation arrangement 960 (see FIG. 17), asealing arrangement 962 (see FIG. 20), a clamping arrangement 910, and aweb tensioning device 875 (see FIG. 17).

Referring to FIG. 14, the web 10 is routed from a supply to and around apair of elongated, transversely extending guide rollers 854. The web 10is then routed to a longitudinally extending guide pin 856. The guidepin 856 is disposed between the inflation edge 20 and the transverseseals 22 of the web 10. The guide pin 856 aligns the web as it is pulledthrough the machine. The web 10 is routed along the guide pin 856through the web tensioning device 875.

The tensioning device 875 keeps the web 10 (see FIG. 17B) taught as theweb is pulled through the machine 50 (see FIG. 17). Keeping the webtaught in the sealing arrangement 962 prevents wrinkles from forming inthe seal 23. The tensioning device can take a wide variety of differentforms. Any arrangement that applies tension to the web 10 can be used.Referring to FIGS. 17A and 17B, in the illustrated embodiment thetensioning device 875 includes a roller 877, a spring loaded pivot arm879, and a shelf member 881. The shelf member 881 is fixed with respectto the path of travel of the web 10. The illustrated shelf member 881includes a substantially horizontal portion 883 and an upwardlyextending portion 885 that extends upward at an obtuse angle from thesubstantially horizontal portion 883.

The substantially horizontal portion 883 and the upwardly extendingportion 885 can take a variety of different forms. In FIG. 17A, acenterline 1252 (the midpoint between the top and the bottom) of theguide pin 856 is depicted. In an exemplary embodiment, an upper surface1260 of the substantially horizontal portion 883 is lower than thecenterline 1252. In the example illustrated by FIG. 17A, an uppersurface 1260 of the substantially horizontal portion 883 is lower than abottom 1262 of the guide pin 856. In FIG. 17A, a horizontal line 1250that is tangent to the top or uppermost surface of the upwardlyextending portion 885 is depicted. In an exemplary embodiment, the topor uppermost surface 1250 is positioned to keep the pocket 23 taughtagainst the guide pin 856, but not so taught that the perforations ofthe pocket 23 break. By pulling the pocket 23 of the web 10 taughtagainst the guide pin 856, wrinkles in the web are eliminated as the webpasses through the sealing arrangement 162. In one exemplary embodiment,the uppermost surface 1250 is positioned at or above the centerline 1252of the guide pin 856. For example, the uppermost surface 1250 may bepositioned at a distance D above the centerline. The distance D may beless than or equal to 0.250 inches, less than or equal to 0.218 inches,less than or equal to 0.187 inches, less than or equal to 0.156 inches,less than or equal to 0.125 inches, less than or equal to 0.093 inches,less than or equal to 0.062 inches, or less than or equal to 0.031inches.

Referring to FIG. 17B, the pivot arm 879 is pivotally mounted to themachine 50 at a pivot 887. A spring 889 is attached to a first end ofthe pivot arm and to the machine 50. The roller 877 is rotatablyattached to the second end of the pivot arm 879. The spring 889 forcesthe roller 877 against the shelf member 881 at the intersection of thesubstantially horizontal portion 883 and the upwardly extending portion885. It should be readily apparent that the roller 877, the pivot arm879 and/or the spring 889 can be replaced with any arrangement thatfrictionally engages the web. The frictional force is selected to keepthe web 10 taught as the web passes through the sealing arrangement 162,but the frictional force is not great enough to cause the web 10 totear. In one exemplary embodiment, the force applied between the roller877 and the shelf 881 is between 5 lbs and 10 lbs, such as about 7 lbsor 7 lbs. The width of the contact area between the roller 877 and theshelf member 881 also influences the frictional force applied to the web10. In one exemplary embodiment, the width of the contact area betweenthe roller 877 and the shelf member 881 is between 0.062 and 0.375inches, between 0.093 and 0.250 inches, between 0.125 and 0.187 inches,about 0.140 inches, or 0.140 inches.

Referring to FIG. 17B, the web 10 is routed between the roller 877 andthe shelf member 881 such that the roller and the shelf memberfrictionally engage the layers 14, 16 of the web 10. The web 10 passesunder the roller 877, up and over the upwardly extending portion 885 ofthe shelf member, and then into the sealing arrangement 962. Thefriction between the web 10, the roller 877, and the shelf member 881keeps the web taught as the web is pulled through the sealingarrangement 962.

The inflation arrangement 960 can take a wide variety of differentforms. Referring to FIG. 17, in the illustrated embodiment, theinflation arrangement 960 includes the hollow, longitudinally extendingguide pin 856 and an inlet opening 1200 for fluid connection to a bloweror other source of air under pressure or other fluid under pressure. Theillustrated guide pin 856 includes a plurality of inflation openings1202. The inflation openings 1202 can take a wide variety of differentforms. In the illustrated embodiment, the guide pin 856 includes afirst, relatively large, opening 1200 and a plurality of smalleropenings 1202. The illustrated opening 1200 is a slot with semi-circularends. The illustrated smaller openings 1202 are circular in shape. Theblower and blower control are disposed in a housing 1204 (FIG. 14) ofthe machine 50.

The sealing arrangement 962 forms the seal 42 to create sealed inflatedcushions 12. The sealing arrangement 962 can take a wide variety ofdifferent forms. Referring to FIGS. 20-22, the sealing assembly 962includes a compliant material 864 and a heated sealing element 865, apositioning device 866, drive rollers 868, idler rollers 869, andsealing belts 870. Each belt 870 is disposed around its respective heatsealing elements 864, 865, drive roller 868, and idler rollers 869. Eachbelt 870 is driven by its respective drive roller 868. In an exemplaryembodiment, the speed of the drive rollers 868 and belts 870 arecontrolled by a belt speed control that is disposed in the housing 1204of the machine. The belt speed control may be part of an overallcontroller for the machine or the belt speed controller may be aseparate device that interfaces with other devices. The belts 870 engageone another, such that the belts 870 pull the web 10 through the heatsealing elements 864, 865. The seal 42 is formed as the web 10 passesthrough the heated sealing elements 864, 865.

Referring to FIG. 26, in the illustrated example the heat sealingelement 864 is biased toward the heat sealing element 865 by a biasingassembly 2100. The biasing assembly 2100 can take a wide variety ofdifferent forms. The biasing arrangement may be any arrangement thatbiases the heat sealing elements 864, 865 relatively toward one another.In the illustrated example, the biasing assembly 2100 includes a supportmember 2101, a shaft member 2102, a spring 2104 disposed around theshaft member, and a coupling member 2106 connected to the heat sealingelement 864. A head 2108 of the shaft member 2102 is disposed in acounterbore 2110 of the support member 2101 with a shaft portion 2112 ofthe shaft member extending through a hole 2114 in the support member2101. The shaft member 2102 is free to move axially in the counterbore.An end of the shaft portion is connected to the coupling member 2106.The spring 2104 pushes the coupling member 2106 and attached heatsealing element 864 downward. The biasing assembly 2100 ensures that theheat sealing elements 864, 865 securely engage the web 10 between thebelts 1070 whenever the belts are engaged.

The heating element 864 can take a wide variety of different forms.Referring to FIG. 26, in the illustrated example the heating element 864includes an outer body 1600, an internal ceramic element 1602, and aninternal thermocouple 1604 or other device for measuring the temperatureof the internal ceramic element 1602. A potting material or otherencapsulating material surrounds the internal ceramic element 1602 andthe thermocouple 1604. In an exemplary embodiment, the thermocouple 1604is disposed directly on the ceramic element 1602. As discussed above, inother embodiments the heating element 864 may also be the wire includingat least one low resistance portion 82 and at least one high resistanceportion 84. The compliant material 112 is included as part of a springloaded clamping assembly 1800, which is discussed below.

A temperature control arrangement is coupled to the thermocouple 1602and the ceramic element 1602 for controlling the temperature of theceramic element 1602 based on feedback from the thermocouple 1604. Thetemperature measured by the thermocouple is used to adjust the powerapplied to the heating element and thereby control the temperature ofthe heating element. The temperature control arrangement is disposed inthe housing 1204 of the machine. The temperature control arrangement maybe part of an overall controller for the machine or the temperaturecontrol arrangement may be a separate device that interfaces with otherdevices.

The heating sealing element positioning device 866 can take a widevariety of different forms. Referring to FIGS. 26 and 27, in theillustrated example the heat sealing element 865 is coupled to the uppersupport members 2101 and a lower support member 2103. The heat sealingelement 865 is fixed to the lower support member 2103. However, thelower heat sealing element may be coupled to the lower support member2103 in any manner. For example, the lower heat sealing element 865 maybe coupled to the lower support member 2103 by a second biasingassembly. In the illustrated embodiment, the heat sealing elementpositioning device 866 (see FIG. 25) comprises two upper actuators 1300,1302 (see FIG. 22) and two lower actuators 1304, 1306 (see FIG. 22). Thetwo upper actuators 1300, 1302 (see FIG. 22) are each operably connectedto the upper support member 2101 and a fixed component of the machine50, such as the housing 1204. The two lower actuators 1304, 1306 areeach operably connected to the lower support member 2103 and a fixedcomponent of the machine 50, such as the housing 1204. The actuators1300, 1302, 1304, 1306 are operable to move the upper and lower supportmembers 2101, 2103 and coupled heat sealing element 865 relativelytoward and away from one another. As such, the heating element 865 ispositioned with respect to the path of travel of the web 10 such thatthe sealing belts 870 selectively engage and disengage the web 10.

Referring to FIGS. 29 and 30, the illustrated upper and lower supportmembers 2101, 2103 include seal cooling portions 2401, 2403. The sealcooling portions 2401, 2403 engage the belts 870 and compress thematerial of the seal downstream of the sealing elements 864, 865. Heatof the seal is transferred through the belts 870 and into the sealcooling portions 2401, 2403 of the support members 2101, 2103 to coolthe material of the seal. The illustrated upper and lower supportmembers 2101, 2103 include optional holes 2410. The holes 2410 increasethe surface area of the upper and lower support members 2101, 2103 toincrease their effectiveness as heat sinks and reduce their weight. Theupper and lower support members 2101, 2103 can be made from a widevariety of different materials. In an exemplary embodiment, the supportmembers are made from a thermally conductive material such as aluminumor copper.

The clamping arrangement 910 is positioned to pinch the top and bottomlayers 14, 16 of the preformed web together. The clamping arrangement910 can take a wide variety of different forms. Referring to FIGS. 23and 24, the clamping arrangement 910 includes drive rollers 1068, idlerrollers 1069, spring loaded clamping assemblies 1800, a clamping portion1802 of the lower support member 2103, and a pair of drive belts 1070.The illustrated clamping portion 1802 of the lower support member 2103includes a support surface 1810 or groove and a lip 1812. The width ofthe support surface 1810 or groove corresponds to the width of the belts1070. The support surface 1810 supports the lower belt 1070 and the lip1812 retains the belt or the support surface.

Referring to FIGS. 29 and 30, each spring loaded clamping assembly 1800includes a clamping member 1900, a shaft member 1902, and a spring 1904disposed around the shaft member. The clamping members 1900, shaftmembers 1902, and springs are coupled to a support member 1901. Eachclamping member 1900 is biased toward the clamping portion 1802 of thelower support portion 2103 by the springs 1902. A head 1908 of eachshaft member 1902 is disposed on the support member 1901 with a shaftportion 1912 of the shaft member extending through a hole 1914 in thesupport member 1901. The shaft member 1902 is free to move axially inthe counterbore. An end of each shaft portion 1912 is connected to aclamping member 1900. The springs 1904 push the clamping members 1900downward. The biasing assemblies 1800 ensure that the belts 1070securely engage the web 10 whenever the belts are engaged.

Each belt 1070 is disposed around its respective drive rollers 1068 andidler rollers 1069. Each belt 1070 is driven by its respective driveroller 1068, which is attached to a drive roller 868. As such, thesealing belts 870 and the pinching belts 1070 are driven in sync. Thebelts 1070 engage one another, such that the belts 1070 pull the web 10and pinch the web as the web moves through the heat sealing element 865.

FIG. 33 illustrates a component diagram of a system 90 including themachine 50. The system 90 includes the rollers 68, belts 70, the heatedsealing element 64 and the compliant material 112. Impulse circuitry 92receives a pulse width modulation (PWM) signal for driving the heatedsealing element 64. A Resistance Measurement Circuitry 94 measurescurrent draw from a known voltage. Therefore, the Resistance MeasurementCircuitry 94 acts as a current sensor (e.g., feedback resistance) fordetermining temperature based on a linear relationship with resistance.In one exemplary embodiment, the temperature of the DC powered heatsealing element 64 is repeatedly calculated at very short timeintervals. For example, the temperature of the DC powered heat sealingelement may be calculated a less than 10 ms, less than 5 ms, less thanor equal to 2 ms, or less than or equal to 1 ms. It is contemplated thatthe system 90 operates at about 281 Hz. If the system operates at about281 Hz, the heated sealing element 64 is monitored between every about 2ms and about 10 ms (e.g., in one embodiment about every 3.56 ms) insteadof about every 20 ms if the system is operated at 50 Hz. Furthermore,although brushed motors are included on the illustration, brushlessmotors are also contemplated. Lines 96, 98 represent the encoderfeedback from the respective rollers 68 driven by the motors. FIG. 34illustrates a cross-sectional view of the compliant material 112 and theheated sealing element (e.g., wire) 64. FIG. 35 illustrates the machine50 with the encoders 81. In this embodiment, the encoders 81 are in thedrive train of the motors 100.

FIGS. 36-39 schematically illustrate another exemplary embodiment of amachine 50 for converting a preformed web to the inflated cushions 12(see FIG. 2A). The machine 50 may take a wide variety of different formsand the inflation, sealing and separation arrangements described belowmay be in the order/positions described or in any other order/positionthat facilitates inflation of the web 10, sealing of the web, andseparation of the web from the machine 50. In the illustrated example,the machine 50 includes an inflation arrangement 160, a sealingarrangement 162, a clamping arrangement 110, a web separation device158, and arms 854 around which the web 10 is fed. A spool mount 204(e.g., spindle) receives a spool including the web material 10.

The inflation arrangement 160 can take a wide variety of differentforms. Any arrangement capable of providing air under increased pressure(above atmosphere) to the pouches 26 can be used. In the illustratedembodiment, the inflation arrangement 160 includes a hollow,longitudinally extending guide pin 56 and a blower 60. A web is routedalong a path indicated by arrows 200 from a supply and the pocket 23 isplaced around the guide pin 56, such that the guide pin 56 is betweenthe inflation side edge 20 and the transverse seals 22. The guide pin 56aligns the web as it is pulled through the machine 50. The guide pin 56includes an inflation opening 102 that is fluidly connected to theblower 60 by a conduit 104. The blower 60 inflates the web pouches 26 asthe web moves past the inflation opening 102.

Belts 70 are provided around respective drive rollers 68. Each belt 70is driven by its respective drive roller 68. The speed of the driverollers 68 and belts 70 are controlled by a belt speed control 67. Thebelts 70 are in close proximity or engage one another, and form a curvedsurface 202 such that the belts 70 pull the web 10 proximate to the heatsealing element 64. The seal 42 (see FIG. 2) is formed as the web passesproximate to the heated sealing elements 64.

In this embodiment, the curved surface 202 optionally eliminates theneed for the compliant material used in the embodiments discussed above.For example, the curved surface 202 results in the two layers 14, 16 ofthe web 10 being more taut as the filled bags pass between the belts 70and move toward the inside of the curve. The relatively more taut layers14, 16 of the web 10 result in a better seal between the two layers 14,16 of the web 10. In another exemplary embodiment, one or both of thebelts 70 are made from a compliant material or one or both of the beltsare backed by a compliant material in addition to having the curvedpath. As the web passes between the heating element and compliantmaterial, imperfections in the web are smoothed by the compliantmaterial and the layers of the web are sealed by the heating element.The compliant or softer material spreads the pressure applied to thesealed area more evenly, which results in a more uniform seal.

With reference to FIG. 40, the spindle 204 for the spool of web materialis illustrated on the machine 50. A cover 206 is illustrated over thebelt 70. The cover 206 pivots around a point 210 to open for loading thebelt. The web follows the path of arrows 200 and encounters aninflection point 212 when travelling through the machine 50.

With reference to FIG. 41, the spindle 204 for the spool of web materialis illustrated on the machine 50. The cover 206 (see FIG. 40) has beenremoved in FIG. 41 so the belt 70 is visible. FIG. 42 illustratesanother view of the machine 50 with one of the belt assemblies removed.The belt 70 that remains is illustrated showing the curved path 202. Themotor 88 and the spindle 204 are also illustrated. FIG. 43 illustratesanother view of the machine 50 showing the spindle 204. FIGS. 44 and 45illustrate another view of the machine 50. In FIG. 45, the arms 854 arenot illustrated so that a nozzle 214 of the inflation arrangement 160may be seen. FIG. 46 illustrates one of the belt assemblies includingthe belt 70 including the cover 206. FIG. 47 illustrates the beltassembly of FIG. 46 with one of the covers removed to show the belt 70.FIG. 48 illustrates another view of the machine 50 showing the blower60, a pulley tensioner 216, and the belt motors 88. FIGS. 49 and 50illustrate different views of the belt assembly showing the curvedsurface 202.

FIGS. 51 and 52 illustrate the spindle 204. FIGS. 53 and 54 illustratethe spool 220 around which the web is wrapped. A clip 222 (see FIG. 52)is used for securing the spool 220 to the spindle 204. In oneembodiment, a radio-frequency identification device (RFID) 224 isincluded on the spool 220. The RFID 224 may be encoded with, forexample, a source of at least one of the spool 220 and the web material10 on the spool 220. The RFID 224 may also be encoded with the type ofweb material 10 (e.g., plastic) on the spool 220. A device (e.g., theencoder 80) on the machine 50 reads a signal from the RFID 224 toconfirm the source of the at least one of the spool 220 and the webmaterial 10 on the spool 220. In one embodiment, if the source of atleast one of the spool 220 and the web material 10 on the spool 220 isnot authorized, the device (e.g., the encoder 80) does not allow themachine 50 to function. In another embodiment, the device (e.g., theencoder 80) on the machine 50 also reads the type of web material 10 onthe spool 220 for determining how the machine 50 will run. The encoder80, for example, may then run the machine 50 at a speed and temperaturesuitable for the web material 10 on the spool 220.

While various inventive aspects, concepts and features of the inventionsmay be described and illustrated herein as embodied in combination inthe exemplary embodiments, these various aspects, concepts and featuresmay be used in many alternative embodiments, either individually or invarious combinations and sub-combinations thereof. Unless expresslyexcluded herein all such combinations and sub-combinations are intendedto be within the scope of the present inventions. Still further, whilevarious alternative embodiments as to the various aspects, concepts andfeatures of the inventions—such as alternative materials, structures,configurations, methods, circuits, devices and components, hardware,alternatives as to form, fit and function, and so on—may be describedherein, such descriptions are not intended to be a complete orexhaustive list of available alternative embodiments, whether presentlyknown or later developed. Those skilled in the art may readily adopt oneor more of the inventive aspects, concepts or features into additionalembodiments and uses within the scope of the present inventions even ifsuch embodiments are not expressly disclosed herein. Additionally, eventhough some features, concepts or aspects of the inventions may bedescribed herein as being a preferred arrangement or method, suchdescription is not intended to suggest that such feature is required ornecessary unless expressly so stated. Still further, exemplary orrepresentative values and ranges may be included to assist inunderstanding the present disclosure, however, such values and rangesare not to be construed in a limiting sense and are intended to becritical values or ranges only if so expressly stated. Moreover, whilevarious aspects, features and concepts may be expressly identifiedherein as being inventive or forming part of an invention, suchidentification is not intended to be exclusive, but rather there may beinventive aspects, concepts and features that are fully described hereinwithout being expressly identified as such or as part of a specificinvention. Descriptions of exemplary methods or processes are notlimited to inclusion of all steps as being required in all cases, nor isthe order that the steps are presented to be construed as required ornecessary unless expressly so stated.

I/We claim:
 1. A machine for converting a web of preformed pouches intoinflated dunnage units, the pouches defined by transverse sealsextending from a remote edge to within a predetermined distance from aninflation edge, the machine comprising: a sealing arrangement positionedto provide a longitudinal seal that intersects the transverse seals toclose the preformed pouches and form a dunnage unit, the sealingarrangement having at least two sealing belts, each belt powered by adrive roller and positioned so that respective first sides engage asurface of the web and pull the web through sealing elements positionedon either side of the web; a heating element on a second side of thefirst belt not engaging the web; a compliant material on a second sideof the second belt not engaging the web; wherein as the web passesbetween the heating element and compliant material, imperfections in theweb are smoothed by the compliant material and the layers of the web aresealed by the heating element.
 2. The machine of claim 1 wherein theheating element includes at least one relatively higher resistanceportion and at least one relatively lower resistance portion.
 3. Themachine of claim 2 wherein the relatively higher resistance portion hasa length of about four inches to about five inches.
 4. The machine ofclaim 2 wherein the relatively lower resistance portion is coated withcopper.
 5. The machine of claim 1 further including: a temperaturecontrol arrangement controlling a temperature of the relatively higherresistance portion.
 6. The machine of claim 1 further wherein thetemperature control arrangement controls the temperature of therelatively higher resistance portion based on a feedback loop thatdetermines a temperature of the relatively higher resistance portionbased on a resistance of the relatively higher resistance portion.
 7. Amachine for converting a web of preformed pouches into inflated dunnageunits, the pouches defined by transverse seals extending from a remoteedge to within a predetermined distance from an inflation edge, themachine comprising: a guide pin for insertion between the transverseseals and the inflation edge to define a path of travel of the web; atensioning device for frictional engagement with the web, wherein thetensioning device holds the web taught during downstream travel; aninflation arrangement for inflation of the preformed pouches; a sealingarrangement positioned to provide a longitudinal seal that intersectsthe transverse seals to close the preformed pouches and form a dunnageunit, the sealing arrangement having at least two sealing belts, eachbelt powered by a drive roller and positioned so that respective firstsides engage a surface of the web and pull the web through sealingelements positioned on either side of the web; a clamping arrangementpositioned to pinch the two layers of the web during travel through thesealing elements, the clamping arrangement having at least two pinchingbelts, each belt powered by a drive roller and positioned to engage asurface of the web and pull the web and pinch the web through thesealing elements; an encoder receiving speeds of the respective belts;wherein if the relative speeds of the respective belts is not within apredetermined tolerance, the encoder determining an error has occurred.8. The machine of claim 7 wherein the encoder adjusts the speeds of therespective belts to maintain the relative speeds within thepredetermined tolerance.
 9. The machine of claim 7 wherein the encoderdetermines the belt speeds based on a feedback from respective motors.